Output Shaft For 5TH, 6TH and Reverse Gear, Dis/Assembling
Output shaft for 5th, 6th and reverse gear, disassembling and assembling
Special tools and equipment
^ VW401 Thrust plate
^ VW402 Thrust plate
^ VW407 Press tool
^ VW408A Press tool
^ VW412 Press tool
^ VW415A Tube
Special tools and equipment
^ VW309 Holding plate
^ VW353 Transmission support
^ VW433 Press piece
^ VW454 Press piece
^ VW457 Support rail
^ VW801 Holding plate
Special tools and equipment
^ VW431 Press piece
^ VW455 Fitting sleeve
^ VW510 Press piece
^ VW516 Tube
^ VW519 Tube
^ 30-11 Thrust plate
Special tools and equipment
^ 40-105 Thrust plate
^ 40-20 Press tool
^ 2050 Thrust piece
^ 3296 Tube
^ VAG1582 Tapered roller bearing puller
^ VAG1582/4 Grip
Special tools and equipment
^ V.A.G 1582/7 Grip
^ 1 - Kukko 21/7 Internal puller
^ 3- Kukko 17/2 Separating device
^ 4 - Kukko 22/2 Counter support
Note:
^ When installing new gears or a new output shaft consult technical data
^ If the output shaft or tapered roller bearings have been replaced then perform output shaft adjustment.
1 - Clutch housing
2 - Shim
^ Always 0.65 mm thick
3 - Outer race/tapered roller bearing
^ Pulling out, Refer to Fig. 1
^ Pressing in, Refer to Fig. 2
4 - Tapered roller bearing inner race
^ Pulling off, Refer to Fig. 8
^ Pressing on, Refer to Fig. 20
5 - Output shaft
^ For 5th, 6th and reverse gear
6 - Reverse gear synchro-hub
^ Pressing off, Refer to Fig. 7
^ Installation position, Refer to Fig. 8
^ Pressing on, Refer to Fig. 10
7 - Securing clip
8 - Reverse gear locking collar
^ Securing clip
9 - Needle roller bearing
^ For reverse gear
10 - Reverse sliding gear
11 - Sleeve
^ Press off with reverse gear, Refer to Fig. 6
^ Installation position: wide shoulder of sleeve faces toward reverse gear
^ Pressing on, Refer to Fig. 11
12 - Securing clip
13 - Needle roller bearing
^ For 6th gear
^ Not in 5-speed manual transmissions
14 - 6th gear
^ Not in 5-speed manual transmissions
15 - 6th gear synchro-ring
^ Not in 5-speed manual transmissions
^ Checking for wear, Refer to Fig. 12
16 - Spacer sleeve
^ For 5-speed manual transmission
^ Pull off together with 5th gear locking collar/synchro-hub after removing securing clip (item - 18 -), Refer to Fig. 5
^ Position toward 5th gear locking collar/synchro-hub, Refer to Fig. 16
^ Press on together with 5th gear locking collar/synchro-hub, Refer to Fig. 17
17 - 5th and 6th gear locking collar with synchro-hub
^ After removing securing clip, press off together with 6th gear (item - 18 -), Refer to Fig. 4 or for 5-speed manual transmission, with spacer sleeve, Refer to Fig. 5
^ Disassembling, Refer to Fig. 13
^ Assembling locking collar/synchro hub Fig. 13 and, Refer to Fig. 14
^ Pressing off in 6-speed manual transmission, Refer to Fig. 15
^ Pressing off in 5-speed manual transmission, Refer to Fig. 17
18 - Securing clip
19 - Needle roller bearing
^ For 5th gear
20 - 5th gear synchro-ring
^ Check for wear, Refer to Fig. 12
21 - Selector gear for 5th gear
22 - Tapered roller bearing inner race
^ Pulling off, Refer to Fig. 3
^ Pressing on, Refer to Fig. 18
23 - Securing clip
^ Redetermine if tapered roller bearing (item - 22 -) or output shaft (item - 5 -) are replaced, Refer to Fig. 19
24 - Outer race/tapered roller bearing
^ Pulling out, Refer to Fig. 21
^ Pressing in, Refer to Fig. 22
25 - Shim
26 - Transmission housing
27 - Spring
^ Installation position, Refer to Fig. 14
28 - Locking collar
29 - Synchro-hub
30 - Locking pieces (Qty. 3)
^ Installation position, Refer to Fig. 13
Fig. 1 Pulling tapered roller bearing outer race out from transmission housing
A - Counter support, e. g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
Note: After pressing out, check washer for damage and replace if necessary.
Fig. 2 Pressing tapered roller bearing outer race into transmission housing
^ Install washer under outer race.
^ Support transmission housing with press tool 40-20 directly below bearing mounting.
Fig. 3 Pulling off tapered roller bearing inner race
^ Before mounting extractor, position press piece VW 431 and thrust plate 40-105 on output shaft.
^ First remove securing clip.
Fig. 4 Pressing off 5th and 6th gear synchro-hub/locking collar with 6th gear
^ First remove securing clip.
Fig. 5 Pressing off 5th gear synchro-hub/locking collar with spacer sleeve
^ First remove securing clip.
Fig. 6 Pressing off sleeve -A- over reverse gear wheel
^ First remove securing clip.
Fig. 7 Pressing off reverse gear synchro-hub
^ First remove securing clip.
A - Separating device 22 to 115 mm, e.g. Kukko 17/2
Fig. 8 Pulling off tapered roller bearing inner race
^ Before mounting extractor, set thrust plate 30-11 on output shaft.
Fig. 9 Installation position of reverse gear synchro-hub
Reverse gear locking collar stop (arrow -A-) faces toward toothing of output shaft (arrow -B-).
Fig. 10 Pressing on reverse gear synchro-hub
^ Install securing clip.
Fig. 11 Pressing on sleeve -A-
Installation position: Wide collar faces toward reverse gear.
^ Install securing clip.
Fig. 12 Checking synchro-ring for 5th and 6th gear for wear
^ Press synchro-ring onto gear cone and measure gap "a" with feeler gauge.
Fig. 13 Disassembling and assembling 5th and 6th gear locking collar and synchro-hub
1 - Spring
2 - Locking piece
3 - Locking collar
4 - Synchro-hub
^ Slide locking collar over synchro-hub.
The recesses for locking pieces in synchro-hub and locking collar must align.
Fig. 14 Assembling 5th and 6th gear locking collar/synchro-hub
The locking collar has been pushed over the synchro-hub.
^ Insert locking pieces and install springs 120- offset. Angled end of spring must locate in hollow locking piece.
Fig. 15 Pressing on 5th and 6th gear locking collar/synchro-hub
^ Install securing clip.
Fig. 16 Positioning spacer sleeve toward 5th gear locking collar/synchro-hub
Lugs (arrow -1-) of spacer sleeve must line up with recesses in synchro-hub (arrow -2-).
Lock pieces (arrow -3-) must rest on collar of spacer sleeve.
Fig. 17 Pressing on 5th gear locking collar/synchro-hub together with spacer sleeve
Fig. 18 Pressing on tapered roller bearing inner race
^ Determine securing clip, Refer to Fig. 19 and install it.
Fig. 19 Determining thickness of circlip
^ Determine thickest circlip which will still fit and install it.
The following securing clips are available:
Fig. 20 Pressing on tapered roller bearing inner race
Fig. 21 Pulling tapered roller bearing outer race out of transmission housing
A - Counter support, e. g. Kukko 22/2
B - Internal puller 46 to 58 mm, e.g. Kukko 21/7
Fig. 22 Pressing tapered roller bearing outer race into transmission housing
^ Support transmission housing with press piece 2050 directly below bearing support.